Dairy-based meat substitute and methods of producing the same

Abstract

Meat substitutes include at least a dried milk product, a carbohydrate, and a liquid such as water. The dried milk product includes one or both of non-fat dry milk and buttermilk powder. The carbohydrate includes one or both of syrup solids, such as corn syrup solids, and a starch, such as modified corn starch. The meat substitutes include amino acids and sugars that undergo a Maillard reaction during preparation of the meat substitutes, yielding flavor compounds in, and non-enzymatic browning of, the meat substitutes. The meat substitutes can be used in the production of food products such as dairy-based jerky.

What is claimed is: 
     
       1. A method of producing a meat substitute, the method comprising:
 blending water with a mixture of at least one dried milk product comprising lactose and protein and at least one carbohydrate to form a gel, wherein the blending is performed at about 6,000 rpm to about 16,000 rpm for about 15 seconds to about 75 seconds such that the at least one dried milk product does not foam; 
 spreading the gel to form a layer such that the gel has a thickness of about 1 mm to about 10 mm; 
 heating the gel layer in a first heating step, wherein the gel is heated at about 210° F. to about 320° F. for about 30 minutes to about 50 minutes; and 
 after the first heating step, heating the gel in a second heating step having a different temperature than the first heating step, wherein the lactose and protein in the at least one dried milk product undergo a Maillard reaction in the second heating step to form the meat substitute, 
 wherein the at least one dried milk product includes non-fat dry milk present at about 38 weight percent to about 43 weight percent of the meat substitute and includes buttermilk powder present at about weight percent to about 10 weight percent of the meat substitute; 
 wherein the at least one carbohydrate includes corn syrup solids having a dextrose equivalent of about 25 to about 55, and the at least one carbohydrate is included at about 26 weight percent to about 70 weight percent of the meat substitute; and 
 wherein the meat substitute comprises a protein content of about 13 weight percent to about 21 weight percent and a fat content of about 1.25 weight percent to about 2.0 weight percent. 
 
     
     
       2. The method of  claim 1 , wherein the Maillard reaction occurs by heating the gel to a temperature of about 300° F. to about 450° F. for about 15 minutes to about 25 minutes. 
     
     
       3. The method of  claim 1 , wherein the Maillard reaction occurs by frying the gel at a temperature of about 275° F. to about 450° F. for about 3 minutes to about 7 minutes. 
     
     
       4. The method of  claim 1 , wherein the at least one carbohydrate further includes corn starch. 
     
     
       5. The method of  claim 1 , wherein the gel is free of a protein isolate. 
     
     
       6. The method of  claim 5 , wherein the gel is free of a whey isolate. 
     
     
       7. The method of  claim 1 , further comprising:
 marinating the meat substitute, and 
 removing moisture from the marinated meat substitute to about  12  weight percent to about 18 weight percent moisture. 
 
     
     
       8. The method of  claim 7 , wherein the moisture is removed from the marinated meat substitute by a third heating step comprising heating the marinated meat substitute at about 140° F. to about 220° F. for about 4.75 hours to about 7.25 hours. 
     
     
       9. A method of producing a meat substitute, the method comprising:
 forming a gel comprising:
 water; and 
 dry components comprising corn syrup solids, corn starch, and one or more of non-fat dry milk and buttermilk powder, wherein the corn syrup solids have a dextrose equivalent of about 42 to about 55 and are present at about 33 weight percent of the dry components, and the corn starch is present at about  10  weight percent of the dry components; 
 
 hydrating and thickening the gel by letting the gel stand for about 4 minutes to about 60 minutes; 
 heating the gel in a first heating step, wherein the gel is heated at about 210° F. to about 320° F. for about 30 minutes to about 50 minutes; and 
 after the first heating step, heating the gel in a second heating step having a different temperature than the first heating step, wherein the non-fat dry milk or buttermilk powder comprise lactose and protein undergo a Maillard reaction in the second heating step to form the meat substitute, 
 wherein the meat substitute comprises a protein content of about 13 weight percent to about 21 weight percent and a fat content of about 1.25 weight percent to about 2.0 weight percent and wherein the meat substitute has crisp texture. 
 
     
     
       10. The method of  claim 9 , wherein the one or more of non-fat dry milk and buttermilk powder is present at about 35 weight percent to about 60 weight percent of the meat substitute. 
     
     
       11. The method of  claim 9 , further comprising, prior to the first heating step, pouring the gel to form a layer such that the gel has a thickness of about 1 mm to about 10 mm. 
     
     
       12. The method of  claim 9 , further comprising:
 marinating the meat substitute, and 
 removing moisture from the marinated meat substitute to about 12 weight percent to about 18 weight percent moisture. 
 
     
     
       13. The method of  claim 12 , wherein the moisture is removed from the marinated meat substitute by a third heating step comprising heating the marinated meat substitute at about 140° F. to about 220° F. for about 4.75 hours to about 7.25 hours. 
     
     
       14. A method of producing a meat substitute, the method comprising:
 admixing water with a dried milk product comprising lactose and protein and a carbohydrate to form an admixture, wherein the carbohydrate includes corn syrup solids having a dextrose equivalent of about 26 to about 30; 
 letting the admixture stand for about 4 minutes to about 60 minutes to form a hydrated, thickened admixture; 
 heating the hydrated, thickened admixture in a first heating step at about 270° F. for about 40 minutes to avoid non-enzymatic browning; and 
 after the first heating step, heating the hydrated, thickened admixture in a second heating step having a different temperature than the first heating step, wherein the hydrated, thickened admixture in the second heating step is heated to about 375° F. for about 20 minutes, and wherein the lactose and protein in the at least one dried milk product undergo a Maillard reaction in the second heating step to form the meat substitute, 
 wherein the meat substitute comprises a dairy-based protein content of up to about  30  weight percent and a lactose content of at least  15  weight percent and 
 wherein the meat substitute has a chewy texture. 
 
     
     
       15. The method of  claim 14 , further comprising the step of forming a layer of the admixture having a thickness of about 1 mm to about 10 mm. 
     
     
       16. The method of  claim 14 , wherein the dried milk product comprises non-fat dry milk and buttermilk powder. 
     
     
       17. The method of  claim 16 , wherein the non-fat dry milk and buttermilk powder are present at about  35  weight percent to about 60 weight percent of the meat substitute. 
     
     
       18. The method of  claim 14 , wherein the meat substitute comprises a moisture content of at least 5 weight percent. 
     
     
       19. The method of  claim 14 , wherein the meat substitute comprises carbohydrates at about 26 weight percent to about 70 weight percent.